Wood-steel composite structural beam

ABSTRACT

A composite structural beam includes a metal frame including frame members extending along at least three axes. The metal frame defines an interior cavity. An internal wood member is located within the interior cavity and is configured to provide structural support to the metal frame. At least one external wood member is connected to the metal frame such that at least a portion of the metal frame is captured between the at least one external wood member and the internal wood member.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 62/233,498, filed Aug. 16, 2021, the contents of which are expressly incorporated herein by reference.

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND 1. Technical Field

The present disclosure relates generally to a structural beam, and more specifically to a composite beam formed of both wood and steel.

2. Description of the Related Art

Structural beams are commonly used in the construction industry to provide strength and stability to a structure. For instance, a beam may be used to support the weight of floors, ceilings, and roofs and may transfer a load to a vertical load bearing element of the structure. Structural beams are commonly formed of wood, due to its availability and ease in forming into the desired size and length. Furthermore, wood is an easy material to work with when attaching additional structures, such as joists, to the beam.

Although wood provides certain advantages as a material for structural beams, there are also some limitations or deficiencies associated with wood. For instance, wood beams may be limited in their ability to span across long lengths and retain their structural characteristics. Accordingly, steel is an alternative material that is commonly used, particularly when a beam with a long span is needed. Steel may also allow for increased strength capacity when compared to wood. However, while steel beams provide certain advantages, there are also disadvantages associated with steel beams. For instance, steel beams tend to be more costly than wood beams, and may be difficult to attach structures, such as joists thereto.

In conventional construction, structural beams typically intersect, or cross paths with air ducts. It tends to be difficult to cut holes in conventional structural beams, while also maintaining the integrity of such beams. As such, in some instances, air ducts may be routed around the structural beams, which may take up valuable space and add additional cost to a construction project.

Accordingly, there is a need in the art for a beam that incorporates that advantages of both steel and wood beams, while also mitigating disadvantages that may be associated with those materials. Various aspects of the present disclosure address this particular need, as will be discussed in more detail below.

BRIEF SUMMARY

In accordance with one embodiment of the present disclosure, there is provided a composite structural beam comprising a metal frame including frame members extending along at least three axes. The metal frame defines an interior cavity. An internal wood member is located within the interior cavity and is configured to provide structural support to the metal frame. At least one external wood member is connected to the metal frame such that at least a portion of the metal frame is captured between the at least one external wood member and the internal wood member.

The frame members may include a first pair of T-bars, with each T-bar including a first portion and a second portion perpendicular to the first portion. The frame members may also include a second pair of T-bars. The internal wood member may be disposed within a central cavity defined by the first and second pairs of T-bars.

The internal wood member may be a laminated wood member. The internal wood member may be sized to extend between opposed portions of the internal cavity such that the internal wood member is in abutting contact with opposed portions of the metal frame.

The frame members may include a first corner bracket having a pair of flanges in orthogonal relation to each other, with the first corner bracket being located at a first end portion of the metal frame. The frame members may include a second corner bracket having a pair of flanges in orthogonal relation to each other, the second corner bracket being located at the first end portion of the metal frame and extending in orthogonal relation to the first corner bracket.

The internal wood member may include a wood member void and the metal frame may include a frame member void aligned with the wood member void. The composite structural beam may additionally include a utility duct aligned with the wood member void and the frame member void. The utility duct may include a collar portion and a plate portion circumnavigating the collar portion. The plate portion may include at least one surface co-planar with a surface of the at least one external wood member.

According to another embodiment, there is provided a modular composite beam comprising a plurality of beam modules. Each beam module includes a metal frame including frame members extending along at least three axes. The metal frame defines an interior cavity. An internal wood member is located within the interior cavity and is configured to provide structural support to the metal frame. At least one external wood member is connected to the metal frame such that at least a portion of the metal frame is captured between the at least one external wood member and the internal wood member.

The present disclosure will be best understood by reference to the following detailed description when read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the various embodiments disclosed herein will be better understood with respect to the following description and drawings, in which:

FIG. 1 is a partially exploded, upper perspective view of a wood-steel composite structural beam;

FIG. 2 is an upper perspective, cross sectional view of a steel frame of the beam of FIG. 1 ;

FIG. 3 is an upper perspective view of a plurality of beams interconnected to each other to form an elongate beam assembly;

FIG. 4 is an upper perspective view of the plurality of beams of FIG. 3 disconnected from each other;

FIG. 5 is a front view of the elongate beam assembly of FIG. 3 ;

FIG. 6 is a front view of the plurality of beams of the elongate beam assembly with the plurality of beams disconnected from each other;

FIG. 7 is an upper perspective view illustrating interconnection of adjacent metal frames in respective structural beams to each other; and

FIG. 8 is an upper perspective view of a plurality of joists connected to the structural beam.

Common reference numerals are used throughout the drawings and the detailed description to indicate the same elements.

DETAILED DESCRIPTION

The detailed description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a wood-steel composite structural beam and is not intended to represent the only forms that may be developed or utilized. The description sets forth the various structure and/or functions in connection with the illustrated embodiments, but it is to be understood, however, that the same or equivalent structure and/or functions may be accomplished by different embodiments that are also intended to be encompassed within the scope of the present disclosure. It is further understood that the use of relational terms such as first and second, and the like are used solely to distinguish one entity from another without necessarily requiring or implying any actual such relationship or order between such entities.

Referring now to the drawings, wherein the showings are for purposes of illustrating preferred aspects of the present disclosure, and are not for purposes of limiting the same, there is depicted a wood-steel composite beam 10 that provides the functional advantages of wood with the strength of steel. The beam 10 may generally include a steel frame 12, as well as an internal wood member 14, and a plurality of external wood members 16, 18. Portions of the steel frame 12 may be captured between the internal wood member 14 and the external wood members 16, 18 to provide lateral support to the steel frame 12 to mitigate buckling thereof. The external wood members 16, 18 may also provide easy to access mounting locations for joists or other structural members that may be attached to the beam.

Referring now first to FIG. 1 , one embodiment of the beam 10 is depicted with the internal wood member 14 being located within the steel frame 12, and the external wood members 16, 18 being exploded from the frame 12 to more clearly illustrate the configuration of the steel frame 12 and the internal wood member 14. As shown more clearly in FIG. 2 , the steel frame 12 may extend along three axes so as to define a length, a width, and a height, with the frame 12 including a pair of upper T-bars 20 arranged in spaced parallel relation to each other, and a pair of lower T-bars 22 arranged in spaced parallel relation to each other. Each T-bar 20, 22 includes a vertical portion and a horizontal portion perpendicular to the vertical portion. Each upper T-bar 20 is arranged with the vertical portion extending toward the opposing lower T-bars 22, and the horizontal portion being generally co-planar with the horizontal portion of the other upper T-bar 20. Likewise, each lower T-bar 22 is arranged with the vertical portion extending toward the opposing upper T-bars 20, and the horizontal portion being generally co-planar with the horizontal portion of the other lower T-bar 22. The vertical portion of the upper and lower T-bars 20, 22 on a common side may be generally co-planar with each other.

The vertical portions of the T-bars 20, 22, and medial segments of the horizontal portions of the T-bars 20, 22 may define an internal cavity 24, within which the internal wood member 14 may reside. In more detail, the internal cavity 24 may be bound by a first plane defined by a first set of aligned vertical portions of the T-bars 20, 22, a second plane define by a second set of aligned vertical portions of the T-bars 20, 22, a third plane defined by the aligned horizontal portions of the upper T-bars 20, and a fourth plane defined by the aligned horizontal portions of the lower T-bars 22.

The steel frame 12 may additionally include several corner brackets 26, 28 (e.g., ninety degree brackets) adjacent end portions of the steel frame 12. In particular, each end portion may include a pair of vertical corner brackets 26, with each vertical corner bracket 26 extending between a lower T-bar 22 and an upper T-bar 20. Each end portion may further include a pair of horizontal corner brackets 28, with each horizontal corner bracket 28 extending across the pair of upper T-bars 20 or the pair of lower T-bars 22. Each corner bracket 26, 28 (e.g., both the horizontal and the vertical) may be connected to the corresponding T-bars 20, 22 via welding, and adhesive, or other mechanical fasteners known in the art.

Referring back to FIG. 1 , the steel frame 12 may further include several lateral struts 30, 32 that extend at an angle between an upper T-bar 20 and a lower T-bar 22. Importantly, one or more voids or openings may be formed between the lateral struts 30, 32 and the T-bars 20, 22, with the opening being sized to accommodate ducting, as will be explained in more detail below.

In the embodiment shown in FIG. 1 , each side of the steel frame 12 includes a set of three outer lateral struts 30 positioned on the outside of the vertical portions of the T-bars 20, 22 with the outer lateral struts 30 extending generally parallel to each other (e.g., extending at a common angle relative to the upper and lower T-bars 20, 22). Each side of the steel frame 12 additionally includes a set of three inner lateral struts 32 positioned on the inside of the vertical portions of the T-bars 20, 22 with the inner lateral struts 32 extending generally parallel to each other, and with a slope that is opposite to that of the outer lateral struts 30. In this regard, in the perspective shown in FIG. 1 , the outer lateral struts 30 extend downwardly in a left to right direction, while the inner lateral struts 32 extend upwardly in a left to right direction. It is understood that the position, number, and orientation of the lateral struts 30, 32 is merely provided as an example, and is not limited thereto without departing from the spirit and scope of the present disclosure.

The steel frame 12 may further include several vertical members 34 on each side of the steel frame 12, with each vertical member 34 extending on the outside of a vertical portion a lower T-bar 22 and a vertical portion of an upper T-bar 20. The vertical members 34 may be positioned adjacent an apex or intersection defined by adjacent lateral struts 30, 32. Although the vertical members 34 are shown as being on the outside of the vertical portions of the T-bars 20, 22, it is contemplated that the vertical members 34 may also be located on the inside of the vertical portions of the T-bars 20, 22 without departing from the spirit and scope of the present disclosure.

The internal wood member 14 may be configured to occupy a substantial portion of the internal cavity 24 of the steel frame 12. In particular, the internal wood member 14 may include a first end face 36 and an opposing second end face 38, with each end face 36, 38 being disposed adjacent an end portion of the steel frame 12. The internal wood member 14 may also include an upper face 40 disposed adjacent the horizontal portions of the upper T-bars 20, and a lower face disposed adjacent the horizontal portions of the lower T-bars 22.

The internal wood member 14 may be specifically contoured to include certain cutouts to define voids or openings within the internal cavity 24. In the embodiment depicted in FIG. 1 , the internal wood member 14 includes a pair of angled faces adjacent respective lower corners of the internal cavity 24, which creates a void or space having a triangularly shaped cross section.

The internal wood member 14 may also include a void or space in a middle region of the internal wood member 14 to accommodate ducting. In the exemplary embodiment, a middle void 42 is defined by an upper segment, a lower segment, and a first inner side surface and an opposing second inner side surface. The inner side surfaces may be generally planar or stepped or define another configuration as may be desired to accommodate the configuration of the steel frame 12, as well as ducting intended to pass through the beam 10. In this regard, the void 42 may be aligned with a space in the steel frame 12 to provide a passageway through both the steel frame 12 as well as the internal wood member 14.

The internal wood member 14 may be a laminated structure or may be formed from one, unitary piece of wood.

The external wood members 16, 18 may include upper wood member 16, and a pair of lateral wood members 18. Although not shown in the drawings, a lower wood member may also be included. The upper wood member 16 includes a plank or board having an outer face, a sidewall extending around the upper wood member 16 and an inner face opposite the outer face. The inner face may include several cutouts or recesses sized to receive corresponding transverse struts 44 or reinforcement members of the steel frame 12. The upper wood member 16 may be attached to the internal wood member 14 via several screws or other mechanical fasteners known in the art. The size and shape of the upper wood member 16 may be substantially similar to the configuration of the upper portion of the steel frame 12, such that the upper wood member 16, when attached to the internal wood member 14, covers much of the upper portion of the steel frame 12. The length of the upper wood member 16 may be substantially equal, yet slightly less, than the distance between the upwardly extending portions of the upper horizontal corner brackets 28.

Each lateral wood member 18 may extend over a respective lateral portion of the steel frame 12. Each lateral wood member 18 may include a plank or board having a lateral face, a sidewall extending around the lateral wood member 18, and a medial face opposite the lateral face. The lateral wood member 18 may be attached to the steel frame 12 or the internal wood member 14 via several screws or other mechanical fasteners known in the art. The size and shape of the lateral wood member 18 may be substantially similar to the configuration of the lateral portions of the steel frame 12. According to one embodiment, one or more portions of the lateral wood member 18 may be cutaway or otherwise configured to create a space adjacent the end portions of the steel frame 12 to facilitate attachment of one beam 10 to an adjacent beam 10, as will be described in more detail below. In the exemplary embodiment, each lateral wood member 18 includes an angled edge to create a triangular space at a lower corner of the beam 10. It is understood that the size, shape and configuration of the space may vary without departing from the spirit and scope of the present disclosure.

The lateral wood member 18 may optionally include one or more integrated components configured to accommodate or facilitate passage of ducting through the beam 10. In the exemplary embodiment, each lateral wood member 18 includes a metal plate 46 integrated therein and connected on either side to wood bodies. The metal plate 46 may include one or more openings formed therein. Each opening may be surrounded by a wall or sleeve 48, 50 sized and configured to facilitate attachment to a duct element. By allowing the ducting to pass through the beam 10, a soffit may be avoided, which may allow for a more efficient use of the available space.

FIGS. 3 and 5 show several beams 10 connected to each other to form a beam assembly 100, while FIGS. 4 and 6 show the beams 10 in a disconnected state. Referring now to FIG. 7 , there is depicted an enlarged view of an end portion of adjacent steel frames 12, with several mechanical fasteners also being shown to illustrate attachment of one beam to an adjacent beam. As can be seen, each vertical corner bracket 26 includes three openings formed therein, each of which accommodates a mechanical fastener, which extends through aligned openings on adjacent vertical corner brackets on beams 10 being attached to each other. An upper horizontal corner bracket 28 may include three openings, which also receive three mechanical fasteners. The lower horizontal corner 28 bracket may only include a pair of openings, as the lower horizontal corner bracket may be smaller than the upper horizontal corner bracket, and may reside between the vertical portions of the lower T-bars.

Each beam 10 may be similarly formed and may be made available in one or more standard lengths, such as eight feet. Thus, multiple beams 10 may be connected to each other to achieve a desired length for the beam assembly 100.

FIG. 8 illustrates connection of joists 60 to the beam 10. The external wood members 16, 18 allow joists 60 to be connected to the beam 10 using hardware 62 commonly used with conventional wood beams, such as joist hangers.

As used herein, the word member may broadly refer to a beam, rod, shaft, plank, or other structural element that may be any size, shape or configuration.

The particulars shown herein are by way of example only for purposes of illustrative discussion, and are not presented in the cause of providing what is believed to be most useful and readily understood description of the principles and conceptual aspects of the various embodiments of the present disclosure. In this regard, no attempt is made to show any more detail than is necessary for a fundamental understanding of the different features of the various embodiments, the description taken with the drawings making apparent to those skilled in the art how these may be implemented in practice. 

What is claimed is:
 1. A composite structural beam comprising: a metal frame including frame members extending along at least three axes, the metal frame defining an interior cavity; an internal wood member located within the interior cavity and configured to provide structural support to the metal frame; and at least one external wood member connected to the metal frame such that at least a portion of the metal frame is captured between the at least one external wood member and the internal wood member.
 2. The composite structural beam recited in claim 1, wherein the frame members include a first pair of T-bars, each T-bar including a first portion and a second portion perpendicular to the first portion.
 3. The composite structural beam recited in claim 2, therein the frame members include a second pair of T-bars.
 4. The composite structural beam recited in claim 3, wherein the internal wood member is disposed within a central cavity defined by the first and second pairs of T-bars.
 5. The composite structural beam recited in claim 1, wherein the internal wood member is a laminated wood member.
 6. The composite structural beam recited in claim 1, wherein the internal wood member is sized to extend between opposed portions of the internal cavity such that the internal wood member is in abutting contact with opposed portions of the metal frame.
 7. The composite structural beam recited in claim 1, wherein the frame members include a first corner bracket having a pair of flanges in orthogonal relation to each other, the first corner bracket being located at a first end portion of the metal frame.
 8. The composite structural beam recited in claim 7, wherein the frame members include a second corner bracket having a pair of flanges in orthogonal relation to each other, the second corner bracket being located at the first end portion of the metal frame and extending in orthogonal relation to the first corner bracket.
 9. The composite structural beam recited in claim 1, wherein the internal wood member includes a wood member void and the metal frame includes a frame member void aligned with the wood member void.
 10. The composite structural beam recited in claim 9, further comprising a utility duct aligned with the wood member void and the frame member void.
 11. The composite structural beam recited in claim 10, wherein the utility duct includes a collar portion and a plate portion circumnavigating the collar portion, the plate portion having at least one surface co-planar with a surface of the at least one external wood member.
 12. A modular composite beam comprising: a plurality of beam modules, each beam module comprising: a metal frame including frame members extending along at least three axes, the metal frame defining an interior cavity; an internal wood member located within the interior cavity and configured to provide structural support to the metal frame; and at least one external wood member connected to the metal frame such that at least a portion of the metal frame is captured between the at least one external wood member and the internal wood member; the plurality of beam modules being configured such that adjacent ones of the plurality of beam modules are engageable with each other.
 13. The modular composite beam recited in claim 12, wherein the frame members of each beam module include a first pair of T-bars, each T-bar including a first portion and a second portion perpendicular to the first portion.
 14. The modular composite beam recited in claim 13, therein the frame members of each beam module include a second pair of T-bars.
 15. The modular composite beam recited in claim 14, wherein the internal wood member is disposed within a central cavity defined by the first and second pairs of T-bars.
 16. The modular composite beam recited in claim 12, wherein the internal wood member is a laminated wood member.
 17. The modular composite beam recited in claim 12, wherein the internal wood member is sized to extend between opposed portions of the internal cavity such that the internal wood member is in abutting contact with opposed portions of the metal frame.
 18. The modular composite beam recited in claim 12, wherein the internal wood member includes a wood member void and the metal frame includes a frame member void aligned with the wood member void.
 19. The modular composite beam recited in claim 18, further comprising a utility duct aligned with the wood member void and the frame member void.
 20. The composite modular composite structural beam recited in claim 19, wherein the utility duct includes a collar portion and a plate portion circumnavigating the collar portion, the plate portion having at least one surface co-planar with a surface of the at least one external wood member. 